Application of experimental design in the synthesis of 1-butanol from ethanol on mixed oxide catalysts at different mg/al molar ratios

1-Butanol, primarily sourced from petroleum, is currently being considered as a viable alternative to gasoline. Various pathways for synthesizing 1-butanol from renewable raw materials have been explored, with a particular focus on the Guerbet reactions. This study aimed to investigate the synthesis of 1-butanol from ethanol using Mg/Al mixed oxides derived from layered double hydroxides with Mg/Al molar ratios of 3:1, 5:1, 8:1, and 10:1. The catalysts were analyzed through X-ray diffraction, X-ray fluorescence, N2 adsorption, scanning electron microscope and energy-dispersive X-ray spectroscopy. Catalytic reaction tests were performed according to a Central Composite Rotatable Design (CCRD) with three replicates at the central point (CP). Among the catalysts tested at CP, the mixed oxides with Mg/Al molar ratios of 3:1 and 5:1 exhibited the most promising results, displaying similar ethanol conversion, and 1-butanol selectivity. This similarity underscores their well-balanced combination of both acidic and basic sites. However, further assessment through a deactivation test revealed that the mixed oxides with Mg/Al molar ratio of 5:1 held the most potential for long-term 1-butanol synthesis from ethanol, thanks to its superior stability and sustained activity. Using this catalyst, other reaction tests were carried out following the CCRD, varying N2 feed flowrate, ethanol molar content in feed flowrate, and temperature. The results indicated that an increase in ethanol conversion directly correlated with higher temperatures, while the 1-butanol selectivity depended on both the N2 feed flowrate, ethanol molar content in feed flowrate, highlighting the importance of a well-balanced combination of both acidic and basic sites.